Treatment of wash/wear wool-containing fabrics

ABSTRACT

THIS INVENTION RELATES TO A COMPOSITION OF MATTER FOR, AND A TREATMENT OF FABRICS MADE OF WOOL AND BLENDS OF WOOL AND OTHER MATERIALS, WHEREBY THE FABRIC HAS A HIGH DEGREE OF CREASE RETENTION AND FABRIC SMOOTHNESS AFTER LAUNDERING BUT IS RESISTANT TO WRINKLES AFTER THE TREATMENT. THE TREATMENT COMPRISES APPLYING TO THE FABRIC AND DRYING A COMPOSITION CONTAINING AS THE ACTIVE INGREDIENTS A METHYLOLATED METHOXY OR HYDROXY LOWER ALKYL CARBAMATE PLUS MELAMINE-FORALDEHYDE OR ITS METHYL ETHER, WITH OR WITHOUT ADDED METHOXY METHYL UREA, THEN FORMING THE DESIRED CREASES OR PLEATS, PRESSING THEM IN PLACE, AND, FINALLY, CURING THE COMPOSITION ON THE FABRIC AT AN ELEVATED TEMPERATURE.

United States Patent 3,565,680 TREATMENT OF WASH/WEAR WOOL- CONTAINING FABRICS Angelo J. Ramunda, Fair Lawn, Joseph T. Bielen, East Paterson, and George D. Maynard, .lr., Bound Brook, N.J., assignors to Millmaster Onyx Corporation, New York, N.Y., a corporation of New York No Drawing. Filed May 20, 1968, Ser. No. 730,648 Int. Cl. D06m 3/02 U.S. Cl. 117141 3 Claims ABSTRACT OF THE DISCLOSURE This invention relates to a composition of matter for, and a treatment of fabrics made of wool and blends of wool and other materials, whereby the fabric has a high degree of crease retention and fabric smoothness after laundering but is resistant to wrinkles after the treatment. The treatment comprises applying to the fabric and drying a composition containing as the active ingredients a methylolated methoxy or hydroxy lower alkyl carbamate plus melamine-formaldehyde or its methyl ether, with or without added methoxy methyl urea, then forming the desired creases or pleats, pressing them in place, and, finally, curing the composition on the fabric at an elevated temperature.

This invention relates to fabrics, garments, and the like which are made from Wool or worsted, and blends of wool and other fibers, and which may or may not be provided with substantially permanent pleats or creases during the manufacture thereof, as fashion dictates, but are resistant to wrinkles and creases occurring thereafter. And it particularly relates to fabrics, garments, and the like, of the aforementioned type, which retain these characteristics after laundering.

Resinous materials were, heretofore, used to provide crease resistance in fabrics made of cellulose or cel ulose blends. However, they were generally not capable of utilization in fabrics made of Wool or wool blends because such materials required the retention of a soft hand and a high pile after cleaning or laundering, and this could not be achieved.

It was then proposed to treat such wool or wool blend fabrics with dimethylol dihydroxy ethyleneurea. Although this treatment did provide some crease retention, it proved commercially unsatisfactory because it produced undesirable felting, unsatisfactory hand, unsatisfactory tensile and tear-strength, unsatisfactory crease-angle recovery, and a most undesirable tendency to yellow white and light-colored fabrics.

These difiiculties are largely overcome by a treatment utilizing methylolated methoxy or hydroxy lower alkyl carbamate esters, such as methylolated methoxy ethyl carbamate, methylolated hydroxy propyl carbamate, etc. However, although this treatment is satisfactory for many conditions, especially when the fabrics are dry-cleaned, it has been found that many of the desirable properties are not retained after the fabric has been subjected to laundering, especially repeated launderings. This is particularly so when the fabric is 100% wool.

It is, therefore, one object of the present invention to provide a treatment for W001 and wool blend fabrics which will not only provide effective crease-retention, wrinkle-resistance, shape retention, soft hand, high pile and freedom from discoloration after dry-cleaning, but also after repeated launderings.

Another object of the present invention is to provide a treatment of the aforesaid type where there is not only Patented Feb. 23, 1971 ice an improved wrinkle-resistance (crease angle recovery) greater than that heretofore attained, but where an exceptionally sharp crease (most desirable in trousers, and the like) is preserved both on the obverse and reverse side of the fabric, even after repeated launderings.

Another object of the present invention is to provide a treatment of the aforesaid type where shrinkage after laundering, even with regard to wool fabrics, is considerably lower than was previously possible.

In accordance with the present invention, the desired properties are achieved by a treatment utilizing (l) methylolated methoxy lower alkyl carbamate esters and their corresponding methyl ethers such as methylolated methoxy ethyl carbamate, methylolated methoxy propyl carbamate and methylolated methoxy isopropyl carbamate; or the corresponding methylolated hydroxy lower alkyl car- 'bamate esters, and (2) melamine-formaldehyde or its methyl ether. The melamine-formaldehyde or its methyl ether may be, in part, substituted by methoxy methyl urea (the methyl ether of either monoor di-methylol urea or mixtures thereof), since this substituent is less expensive and would reduce the cost. However, aside from cost, the use of the melamine-formaldehyde or its methyl ether, without any part thereof substituted, is preferable.

It is possible, but less preferable, to use methylolated lower alkyl carbamate wherein there is no methoxy or hydroxy group present, such as methylolated methyl carbarnate, methylolated ethyl carbarnate, etc., but the methoxy or hydroxy compounds are much more preferable because they do not decompose to produce any odor in the fabric and because they provide improved physical characteristics, particularly with regard to hand, color retention, tensile strength and tear strength.

Fabrics sensitized with the compositions of matter of this invention may be bonded to acetate, nylon or other suitable fabric with various adhesives under normal conditions, i.e., by applying the adhesive to the wool or wool blend fabric, attaching the suitable backing fabric, and setting the bond by means of pressure alone, or of pressure and heat.

Where heating is necessary for the purpose of lamination, the products of this invention may safely be applied to sensitize the face fabric without danger of effecting an undesirable level of pre-cure in the course of the lamination process.

The lamination may also be carried out, if it is so desired, before the process of sensitization.

The fabrics treated with the above combination of agents may consist entirely of wool, or of wool blends containing also such diverse fibers as rayon or regenerated cellulose, cotton, cellulose acetates, both the triacetate and partially hydrolyzed acetate, nylon, Dacron, Kodel, or other polyesters and other synthetic fibers. The fabrics may be homogeneous, or two fabrices may be laminated, as described in the examples to follow:

The test methods used were as follows:

(A) From the Federal Specification, Textile Test Methods:

(1) Tear strength-Method CCC-T-19lB-5l32 (2) Tensile strengthMethod CCC-Tl9lB-5l02 (B) From the 1966 Technical Manual of the Ameri can Association of Textile Chemists and Colorists:

(l) Crease retention ratingA.A.T.C.C. Method N0.

88-C-l964T (2) Seam retention rating-A.A.T.C.C. Method No. 88-

Bl964T (3) Smoothness ratingA.A.T.C.C. Method No. 88-

A-l964T (4) Monsanto crease angle recovery-A.A.T.C.C. Method No. 66-1959T (C) From the Westinghouse Electric Corporations Manual, Standard Home Laundering at 140 F., the Westinghouse Laundromat.

(1) Shrinkage percent The following examples, which illustrate both the preparation of the compounds of the present invention and treatments utilizing such compounds, are intended for creased and pressed at 280 F. Three samples were cured as follows:

(A) 8 minutes at 325 F. ('B) 10 minutes at 315 F. (C) 10 minutes at 325 F.

A black fabric of the same type was also treated in this manner; color retention was excellent.

The tan fabric was tested as follows:

. TABLE I illustrative purposes only and not for limitation of the invention except as claimed. In the treatment of the Tensile 222? l gf fabrics, the fabrics were routinely scoured to remove s m strcngtfili, nn), %xffii dcgtrctcsi sizing, oil and other intermediate finishing agents, and a p gmms l 0 a Pressaiid cui'e,A 27115. 864 753 200 were then rinsed to a slightly acid condition to avoid Press and cureh 2611). 768 852 289 inactivation or depletion of the catalyst by alkaline mat- Press and cure, o. 2511). (30s 399 288 ter. They were then treated with the composi i n em- %,,5,} 3% i113 ""5 bodying the present invention:

TABLE 1(a) Percent shrinkage W/W, 140 F., Crease Retention, 1 wash 5 washes, tumble dry 140 11, tumble dry 120 F., 140 F., warpx 'WEJJDX Sample lwash 5washes lwash 5Washes fill fill A 4.5 4.5 5 5 0.5x1.0 0111.0 B 4.2 4 5 5 0.5x1.0 0111.0 0 4.2 4.2 5 5 0.5x1.0 0.25x1.0 Unfinished 3. 2 2. 8 2 1 6 x 8 7. x 8. 75

EXAMPLE 1 EXAMPLE 4 Component: Parts by wt. A white Viyella shirting fabric consisting of 45% cot- .Methylolated methoxy ethyl carbamate (about ton and 55% wool was treated with the bath of Exam- 8()% active) 1 ple 1 to 93% wet pickup and dried at 250270 F. and Melamine-formaldehyde methyl oth r (a ut stored for a period of about six months; a part of the 75% active) 3- fabric was reserved for processing, on the same day, that Methyl-salt catalyst 1 is, without aging. active, reactive acrylic emulsloll The sensitized and aged fabric was processed in the 40% active P y y Softener same manner as the swatches worked up on the same day.

Nonionic wetting agent (alkyl phenol polyglycol ether) Water to make 100.0.

The catalyst and the softener are both standard in the art and need not further be described.

The above components were mixed together at room temperature and pressure, preferably between 60 and 110 F., to form a treating bath.

If desired, the melamine-formaldehyde methyl ether content may be as low as 0.5%, or as high as 10%, but, preferably, from 1% to 5%, in a formula such as the above, the amount of water being changed accordingly. However, the 3% content gives optimum effects.

EXAMPLE 2 A blue-green plaid fabric, a blend of /50 wool/rayon was impregnated with the bath of Example 1 to give 80% wet-pickup on a two-roll pad, after which it was dried at 250 F.-270 F. to dryness.

The sensitized fabric was stored on a roll under ambient conditions for a period of six-months. Thereafter, swatches were cut and pressed with a pleat or a crease at 280 F. on a Prosperity Model 249 MU programmed trouser-leg presser, at five seconds steam, 10 seconds bake and 5 seconds vacuum. They were then cured for ten minutes at 320 F.

A series of minor variations in the proportions given in the formulation of Example 1 indicated that, as so composed, it yielded the best crease retention, with a rating of 5, and a rating of 5 for the wash/wear appearance in each case after both one and five homelaunderings at 140 F., followed by tumble-drying at ISO-170 F.

EXAMPLE 3 The bath of Example 1 was applied in the same manner to a tan mens slack-weight fabric consisting of 50% wool, 40% rayon and 10% nylon.

The sensitized goods were stored on a roll as above, for delayed cure for a period of six months. It was then A seam was sewn, and a pleat or a crease was pressed at 280 F., after which the swatches were cured for ten minutes at 320 F.

Excellent whiteness was obtained in both the immediate and delayed cure samples. The latter tested as follows:

The White Viyella fabric of Example 4 was padded and dried in the same way, and was then precured to the extent of at least as follows:

Sample A for 2 minutes at 340 F. Sample B for 1% minutes at 340 F. Sample C for 1% minutes at 320 F. Sample D for 2 minutes at 320 F.

for temporary, or long-lasting crease-retention.

The swatches were then sewn, pleated and pressed at a temperature of from 280 to 340 F.

The fabric performance with respect to appearance crease-retention and shrink-resistance were fully acceptable according to industry standards.

TABLE IV Crease reteu- Percent shrinkage WIW tion W x F 1 wash 5 washes 1 wash 5 washes I wash 5 washes Sample A 5.0 4.8 5.0 5.0 3.51:0.5 5.0x0.5 B 5.0 4.8 5.0 5.0 6.51:1.5 8.51:2.5

EXAMPLE 6 EXAMPLE 10 A bath was prepared as follows. 10 A grey, 100% woolen worsted fabric was padded with Component; parts by Wt the bath of Example 6 and dried and stored on a roll for Methylolated methoxy ethyl carbamate (about 80% active) 20.6 Melamine-formaldehyde methyl ether (about 75% active) 4.4 40% active, reactive acrylic emulsion 4.0 40% active polyethylene softener 3.0 Metal-salt catalyst 12.5 Nonionic wetting agent (alkyl phenol polyglycol ether) 2 Water to make 100.0. The above components were mixed together as in Example 1.

EXAMPLE 7 A woven, womens suiting weight fabric composed of one-third each of wool, Kodel (polyester) and rayon, laminated to tri-acetate tricot, was padded with the bath of Example 6 and in the same manner as in Example 2, dried at 250 F. essentially to dryness, and stored on a roll for a period of six months.

Swatches were cut and pressed with a crease or pleat at 280 F., as in Example 2, and cured for 8 minutes at 325 F. They were tested, as follows, the washings be ing at 140 F. followed by tumble-drying. The three samples differed only in color, pattern and weave, A being a blue tweed, B a grey/red/gold small plaid and C a grey/red/ gold large plaid:

a period of months before curing.

Swatches were pressed with a crease at 280 F., and cured for ten minutes at 310 F. They were then subjected to laundering at 140 F. and tumble-dried at 140 F. They tested as follows:

TABLE V W/W:

I wash 4.0 5 washes 3.8 Crease retention:

I wash 4+ 5 washes 4+ Percent shrinkage, W x F:

I wash 2.0x 1.0 5 washes 2.5x 1.0

EXAMPLE 11 The fabric of Example 2 was treated with a bath similar to that of Example 1, with the exception that the resin content was replaced in part with a 75% active methoxy methyl urea (methyl ether of a mixture of the monoand di-methylol urea).

Performance tests showed mainly an appreciable decrease in crease-retention, while other characteristics were affected to a lesser degree.

The above substitution in part is strictly an economy measure, and, as expected, one or more of the desired TABLE III Wrinkle Crease reten- Percent shrinkage reeortleiy, Wash/wear tion warp x fill 0 degrees 1 wash 5 Washes 1 wash 5 washes I wash 5 washes Sample A 301 4.8 4.8 5.0 5.0 3.5x1.0 4.0x0.5 B 285 4.8 4.8 5.0 5.0 2.0x1.0 2.5x1.0 C 282 4.8 4.8 5.0 5.0 2.02:1.5 3.02:1.5

EXAMPLE 8 effects are diminished. This may be desirable where the Wool or wool-blend fabrics intended for lamination Were sensitized and dried as in the previous examples, after which a suitable bonding agent was applied, and the backing fabric was then placed in contact with it. The laminate package was then subjected to temperatures ranging from 2-80310 F., for from one to three minutes in order to dry and cure the adhesive to achieve a suitable fabric-to-fabric bond.

The sensitized and bonded fabric was then pressed and cured as in previous examples, both on the same day and also after extended storage. The results were similar to those of Example 8.

This demonstrates the feasibility of sensitizing and then laminating without effecting a premature cure.

EXAMPLE 9 (A) A 41% wool, 29% rayon, 16% cotton and 14% polyester black and white tweed, womens suiting was padded with the bath of Example 6, at about 80% wet pickup and dried at 250-270 F. essentially to dryness. It was then stored for a period of five months. Samples were then pressed with a pleat in the same manner as before at 280 F. and cured for 8 minutes at 325 F.

(B) In the same way, a womens suiting fabric of a closer, black and white tweed pattern and containing 61% wool, 16% cotton, 15% rayon and 8% nylon was treated in the same way. They tested as follows:

The launderings were carried out at 140 F., followed by tumble-drying at 140 F.

said effects may be of minor importance for cheaper goods.

In the above examples, where a crease was pressed into the fabric, the crease remained exceptionally sharp even after repeated launderings, and whether examined from the obverse or reverse side of the swatch.

This remarkably sharp crease, such as would be especially appropriate as a trouser crease, was obtained even in the case of the woolen fabric of Example 10.

Obviously, many modifications of the present invention are possible in the light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.

The invention claimed is:

1. A method of treating fabrics containing woolen fibers which comprises impregnating the fabric with a treating composition containing as the active ingredient an aqueous mixture consisting essentially of (a) a methylolated lower alkyl carbamate and (b) a member of the group consisting of melamine-formaldehyde condensate and its methyl ether, the carbamate constituting from about 17 to about 21 percent by weight and the melamineforrnaldehyde resin or its methyl ether constituting from about 0.5 to about 10 percent by weight of the composition, and drying the impregnated fabric.

2. The method of claim 1 wherein the methylolated lower alkyl carbamate is a member of the group consisting of methylolated methoxy lower alkyl carbamate 3,087,837 4/1963 Van Loo et a1 l17139.4 and methylolated hydroxy lower alkyl carbamate. 3,144,299 8/1964 Prick et al 8-1163 3. The method of claim 1 wherein the melamine-for- 3,369,858 2/1968 Lourigan et a1. 81l6.3 maldehyde or its methyl ether is partially substituted 3,454,423 7/1969 Cohen et al. l17-139.4X by methoxy methyl urea. 5

MURRAY KATZ, Primary Examiner References Cited T. G. DAVIS, Assistant Examiner UNITED STATES PATENTS 2,933,409 4/1960 Blinkley et al. 117 11 2,950,553 8/1960 Hurwitz 117139.4X 1O 1l7l39.4, 161; 8127.6 

